Login| Sign Up| Help| Contact|

Patent Searching and Data


Title:
SYSTEMS AND METHODS FOR AUTOMATIC ELECTRICAL WIRING WITH AN END-EFFECTOR
Document Type and Number:
WIPO Patent Application WO/2022/123558
Kind Code:
A1
Abstract:
An aspect of some embodiments of the invention relates an automatic system for electrical wiring comprising at least one wiring arm module comprising a wiring-end effector at its distal end for manipulating wires to be inserted in an object in need of electrical wiring; and circuitry, which coordinates the operation of said at least one wiring arm module using at least one parameter related to said need of electrical wiring.

Inventors:
EINAV OMER (IL)
SHABANOV DORON (IL)
EISENBERG ROM (IL)
MANDELBAUM ORYA (IL)
EFRAT YOTAM (IL)
Application Number:
PCT/IL2021/051451
Publication Date:
June 16, 2022
Filing Date:
December 07, 2021
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
POLYGON T R LTD (IL)
International Classes:
H01R43/20; B25J9/16; B25J15/04; B25J19/02; H01R13/631; H01R13/641
Foreign References:
US20190329403A12019-10-31
US20200290206A12020-09-17
US20160249991A12016-09-01
US4936011A1990-06-26
US4883939A1989-11-28
US20170327167A12017-11-16
US20140360832A12014-12-11
US20160288322A12016-10-06
US20180264660A12018-09-20
US20200161028A12020-05-21
Attorney, Agent or Firm:
EHRLICH, Gal et al. (IL)
Download PDF:
Claims:
27

WHAT IS CLAIMED IS:

1. An automatic system for electrical wiring comprising: a. at least one wiring arm module comprising a wiring-end effector at its distal end for manipulating wires to be inserted in a hole of an electrical connector; b. circuitry, which coordinates the operation of said at least one wiring arm module and said wiring-end effector using at least one parameter related to said electrical connector; c. one or more sensors configured to detect a parameter related to a wire while being inserting in said hole of said electrical connector by said wiring-end effector.

2. The automatic system for electrical wiring according to claim 1, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.

3. The automatic system for electrical wiring according to claim 1, wherein said wiring-end effector comprises a wire holding element.

4. The automatic system for electrical wiring according to claim 3, wherein said wire holding element comprises a wire pinching element comprising two extensions.

5. The automatic system for electrical wiring according to claim 4, wherein said two extensions are two elongated extensions.

6. The automatic system for electrical wiring according to claim 4, wherein said two extensions are brought together by an electrical mechanism.

7. The automatic system for electrical wiring according to claim 4, wherein said two extensions are brought together by a pneumatic mechanism.

8. The automatic system for electrical wiring according to claim 3, wherein said wire holding element comprises a motor for movement along an entry axis of an electrical terminal connector in said object.

9. The automatic system for electrical wiring according to claim 3, wherein said wiring-end effector comprises one or more sensors for monitoring forces applied on said wire holding element.

10. The automatic system for electrical wiring according to claim 1, wherein said wiring-end effector comprises a wire locking element.

11. The automatic system for electrical wiring according to claim 10, wherein said wire locking element comprises an electrical terminal connector locking mechanism actuator.

12. The automatic system for electrical wiring according to claim 11, wherein said wire locking element comprises one or more motors to move said actuator in one or more directions for interacting with a locking mechanism in an electrical terminal connector.

13. The automatic system for electrical wiring according to claim 10, wherein said wire locking element comprises one or more torque sensors for monitoring the locking actuation of said wire locking element on a locking mechanism in an electrical terminal connector.

14. The automatic system for electrical wiring according to claim 13, wherein said wire locking element is configured to actuate said a locking mechanism in said electrical terminal connector according to predetermined torqueing parameters monitored by said torque sensors.

15. The automatic system for electrical wiring according to claim 1, wherein said circuitry receives said at least one parameter related to said electrical connector from one or more of an electronic device, a computer, a tablet, a cellphone and a server.

16. The automatic system for electrical wiring according to claim 1, further comprising a monitoring system.

17. The automatic system for electrical wiring according to claim 16, wherein said monitoring system comprises one or more cameras.

18. The automatic system for electrical wiring according to claim 16, wherein said monitoring system comprises one or more sensors.

19. The automatic system for electrical wiring according to claim 16, wherein said monitoring system comprises one or more force sensors.

20. The automatic system for electrical wiring according to claim 16, wherein said monitoring system comprises one or more torque sensors.

21. The automatic system for electrical wiring according to claim 16, wherein said monitoring system comprises one or more current sensors.

22. The automatic system for electrical wiring according to claim 1, further comprising said object in need of electrical wiring.

23. The automatic system for electrical wiring according to claim 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring from the side.

24. The automatic system for electrical wiring according to claim 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring along the terminal wire port angle.

25. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

26. The wiring end effector according to claim 25, wherein said two extensions are two elongated extensions.

27. The wiring end effector according to claim 25, wherein said at least one sensor is located in said wire holding element.

28. The wiring end effector according to claim 25, wherein said at least one sensor is located in said two extensions.

29. The wire end effector according to claim 25, further comprising a wire locking element comprising an electrical terminal connector locking mechanism actuator.

30. A method of automatic connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.

31. The method according to claim 30, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.

32. The method according to claim 30, wherein said inserting is performed by moving said wire holder.

33. The method according to claim 30, wherein said inserting is performed by moving said connector.

34. The method according to claim 30, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.

35. The method according to claim 30, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.

36. The method according to claim 30, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism. 31

37. The method according to claim 30, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.

38. The method according to claim 37, wherein said assessing comprises sensing if said at least one wire resists said pulling back.

39. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a locking device comprising an electrical terminal connector locking mechanism actuator.

40. The wiring end effector according to claim 39, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

41. A wiring end effector, comprising: a. a wire holding element comprising two extensions; b. a locking device comprising an electrical terminal connector locking mechanism actuator; c. a wire feeder configured to feed at least one wire to said wire holding element.

42. The wiring end effector according to claim 41 , further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

43. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a camera configured to monitor the actions of said wire holding element.

44. The wiring end effector according to claim 43, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.

45. The wiring end effector according to claim 43, further comprising a wire feeder configured to feed at least one wire to said wire holding element. 32

46. The wiring end effector according to claim 43, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

47. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a wire cutter configured to cut a distal of a wire being held by said wire holding element.

48. The wiring end effector according to claim 47, further comprising a camera configured to monitor the actions of said wire holding element.

49. The wiring end effector according to claim 47, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.

50. The wiring end effector according to claim 47, further comprising a wire feeder configured to feed at least one wire to said wire holding element.

51. The wiring end effector according to claim 47, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

52. A method of automatic wiring a lightning unit by connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.

53. The method according to claim 52, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire. 33

54. The method according to claim 52, wherein said inserting is performed by moving said wire holder.

55. The method according to claim 52, wherein said inserting is performed by moving said connector.

56. The method according to claim 52, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.

57. The method according to claim 52, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.

58. The method according to claim 52, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism.

59. The method according to claim 52, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.

60. The method according to claim 59, wherein said assessing comprises sensing if said at least one wire resists said pulling back.

Description:
SYSTEMS AND METHODS FOR AUTOMATIC ELECTRICAL WIRING WITH

AN END-EFFECTOR

RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Patent Application No. 63/122,030 filed on 7 December 2020, U.S. Provisional Patent Application No. 63/164,645 filed on 23 March 2021 and U.S. Provisional Patent Application No. 63/164,660 filed on 23 March 2021 the contents of which are incorporated herein by reference in their entirety.

This application is also related to co-filed PCT Patent Application entitled “SYSTEMS AND METHODS FOR AUTOMATIC ELECTRICAL WIRING” (Attorney Docket No. 90344), the contents of which are incorporated herein by reference in their entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to systems and methods for automatic electrical wiring and, more particularly, but not exclusively, to systems and methods for automatic insertion of electrical wires into electrical terminal connectors.

Preparation and wiring of electrical panels comprises a complicated process of wire architecture design and hard wiring labor. The present invention discloses systems and methods for automatic insertion of electrical wires into electrical terminal connectors, which can also be optionally used, for example, for systems and methods for automatic electrical wiring of panels.

SUMMARY OF THE INVENTION

Following is a non-exclusive list including some examples of embodiments of the invention. The invention also includes embodiments which include fewer than all the features in an example and embodiments using features from multiple examples, also if not expressly listed below.

Example 1. An automatic system for electrical wiring comprising: a. at least one wiring arm module comprising a wiring-end effector at its distal end for manipulating wires to be inserted in a hole of an electrical connector; b. circuitry, which coordinates the operation of said at least one wiring arm module and said wiring-end effector using at least one parameter related to said electrical connector; c. one or more sensors configured to detect a parameter related to a wire while being inserting in said hole of said electrical connector by said wiring-end effector. Example 2. The automatic system for electrical wiring according to example 1, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.

Example 3. The automatic system for electrical wiring according to example 1, wherein said wiring-end effector comprises a wire holding element.

Example 4. The automatic system for electrical wiring according to example 3, wherein said wire holding element comprises a wire pinching element comprising two extensions.

Example 5. The automatic system for electrical wiring according to example 4, wherein said two extensions are two elongated extensions.

Example 6. The automatic system for electrical wiring according to example 4, wherein said two extensions are brought together by an electrical mechanism.

Example 7. The automatic system for electrical wiring according to example 4, wherein said two extensions are brought together by a pneumatic mechanism.

Example 8. The automatic system for electrical wiring according to example 3, wherein said wire holding element comprises a motor for movement along an entry axis of an electrical terminal connector in said object.

Example 9. The automatic system for electrical wiring according to example 3, wherein said wiring-end effector comprises one or more sensors for monitoring forces applied on said wire holding element.

Example 10. The automatic system for electrical wiring according to example 1, wherein said wiring-end effector comprises a wire locking element.

Example 11. The automatic system for electrical wiring according to example 10, wherein said wire locking element comprises an electrical terminal connector locking mechanism actuator.

Example 12. The automatic system for electrical wiring according to example 11, wherein said wire locking element comprises one or more motors to move said actuator in one or more directions for interacting with a locking mechanism in an electrical terminal connector.

Example 13. The automatic system for electrical wiring according to example 10, wherein said wire locking element comprises one or more torque sensors for monitoring the locking actuation of said wire locking element on a locking mechanism in an electrical terminal connector.

Example 14. The automatic system for electrical wiring according to example 13, wherein said wire locking element is configured to actuate said a locking mechanism in said electrical terminal connector according to predetermined torqueing parameters monitored by said torque sensors. Example 15. The automatic system for electrical wiring according to example 1, wherein said circuitry receives said at least one parameter related to said electrical connector from one or more of an electronic device, a computer, a tablet, a cellphone and a server.

Example 16. The automatic system for electrical wiring according to example 1, further comprising a monitoring system.

Example 17. The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more cameras.

Example 18. The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more sensors.

Example 19. The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more force sensors.

Example 20. The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more torque sensors.

Example 21. The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more current sensors.

Example 22. The automatic system for electrical wiring according to example 1, further comprising said object in need of electrical wiring.

Example 23. The automatic system for electrical wiring according to example 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring from the side.

Example 24. The automatic system for electrical wiring according to example 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring along the terminal wire port angle.

Example 25. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

Example 26. The wiring end effector according to example 25, wherein said two extensions are two elongated extensions.

Example 27. The wiring end effector according to example 25, wherein said at least one sensor is located in said wire holding element.

Example 28. The wiring end effector according to example 25, wherein said at least one sensor is located in said two extensions. Example 29. The wire end effector according to example 25, further comprising a wire locking element comprising an electrical terminal connector locking mechanism actuator.

Example 30. A method of automatic connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.

Example 31. The method according to example 30, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.

Example 32. The method according to example 30, wherein said inserting is performed by moving said wire holder.

Example 33. The method according to example 30, wherein said inserting is performed by moving said connector.

Example 34. The method according to example 30, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.

Example 35. The method according to example 30, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.

Example 36. The method according to example 30, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism.

Example 37. The method according to example 30, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.

Example 38. The method according to example 37, wherein said assessing comprises sensing if said at least one wire resists said pulling back.

Example 39. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a locking device comprising an electrical terminal connector locking mechanism actuator.

Example 40. The wiring end effector according to example 39, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

Example 41. A wiring end effector, comprising: a. a wire holding element comprising two extensions; b. a locking device comprising an electrical terminal connector locking mechanism actuator; c. a wire feeder configured to feed at least one wire to said wire holding element.

Example 42. The wiring end effector according to example 41 , further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

Example 43. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a camera configured to monitor the actions of said wire holding element.

Example 44. The wiring end effector according to example 43, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.

Example 45. The wiring end effector according to example 43, further comprising a wire feeder configured to feed at least one wire to said wire holding element.

Example 46. The wiring end effector according to example 43, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

Example 47. A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a wire cutter configured to cut a distal of a wire being held by said wire holding element.

Example 48. The wiring end effector according to example 47, further comprising a camera configured to monitor the actions of said wire holding element.

Example 49. The wiring end effector according to example 47, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.

Example 50. The wiring end effector according to example 47, further comprising a wire feeder configured to feed at least one wire to said wire holding element. Example 51. The wiring end effector according to example 47, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.

Example 52. A method of automatic wiring a lightning unit by connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.

Example 53. The method according to example 52, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.

Example 54. The method according to example 52, wherein said inserting is performed by moving said wire holder.

Example 55. The method according to example 52, wherein said inserting is performed by moving said connector.

Example 56. The method according to example 52, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.

Example 57. The method according to example 52, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.

Example 58. The method according to example 52, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism.

Example 59. The method according to example 52, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.

Example 60. The method according to example 59, wherein said assessing comprises sensing if said at least one wire resists said pulling back. Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

As will be appreciated by one skilled in the art, some embodiments of the present invention may be embodied as a system, method or computer program product. Accordingly, some embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, some embodiments of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon. Implementation of the method and/or system of some embodiments of the invention can involve performing and/or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of some embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware and/or by a combination thereof, e.g., using an operating system.

For example, hardware for performing selected tasks according to some embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to some embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to some exemplary embodiments of method and/or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic hard-disk and/or removable media, for storing instructions and/or data. Optionally, a network connection is provided as well. A display and/or a user input device such as a keyboard or mouse are optionally provided as well.

Any combination of one or more computer readable medium(s) may be utilized for some embodiments of the invention. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.

A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electromagnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.

Program code embodied on a computer readable medium and/or data used thereby may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

Computer program code for carrying out operations for some embodiments of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (FAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

Some embodiments of the present invention may be described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.

The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

Some of the methods described herein are generally designed only for use by a computer, and may not be feasible or practical for performing purely manually, by a human expert. A human expert who wanted to manually perform similar tasks, such as the insertion of wires into sockets/terminals/connectors, might be expected to use completely different methods, e.g., making use of expert knowledge and/or the pattern recognition capabilities of the human brain, which would be vastly more efficient than manually going through the steps of the methods described herein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced. In the drawings:

Figures 1 A-E are schematic representations of an exemplary method of inserting a wire into an electrical terminal connector when performed by a human;

Figure 2 is a schematic representation of an exemplary wiring arm module, according to some embodiments of the invention;

Figure 3A is a schematic representation of exemplary wiring-end effector module, according to some embodiments of the invention;

Figure 3B is a schematic representation of an exemplary wire holding element of an exemplary wiring-end effector module, according to some embodiments of the invention;

Figure 3C is a schematic representation of the sensors located on the extensions, according to some embodiments of the invention;

Figures 3D-E are schematic representations of exemplary gimbal blocks to which the extensions are connected, according to some embodiments of the invention;

Figure 3F is a schematic representation of an exemplary wire locking element, according to some embodiments of the invention;

Figure 3G are schematic representations of exemplary possible interactions of wiring-end effector modules with different types of electrical terminal connector locking mechanisms, according to some embodiments of the invention;

Figures 3H-I are schematic representations of exemplary wire end-effector of the automated electrical wiring system, according to some embodiments of the invention;

Figure 3J is a schematic close view of the gripper and the extensions, according to some embodiments of the invention;

Figure 3K is a schematic representation of an exemplary wiring-end effector module comprising a camera, according to some embodiments of the invention;

Figures 4A-B are schematic representations of exemplary ferrules, according to some embodiments of the invention;

Figures 5A-C are flowcharts of an exemplary method of wiring by an exemplary wiringend effector module, according to some embodiments of the invention;

Figure 6 is a schematic representation of an automated electrical wiring for lightning units, according to some embodiments of the invention;

Figure 7 is a graph describing the exemplary phases of the insertion of a wire into an electrical terminal connector as identified by the sensors in the gripper, according to some embodiments of the invention; Figures 8A-C are three different examples of sensed forces by the gripper in three different scenarios, according to some embodiments of the invention; and

Figure 9 illustrates a plurality of test experiments for the characterization of exemplary scenarios, according to some embodiments of the invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to systems and methods for automatic electrical wiring and, more particularly, but not exclusively, to systems and methods for automatic insertion of electrical wires into electrical terminal connectors.

Overview

An aspect of some embodiments of the invention relates to automated wiring of an electrical panel and performing the connection of the wires to the connectors by automated machines. In some embodiments, the automated wiring machines comprise a plurality of sensors for tactile feedback, which potentially increases the insertion process robustness of wires in their correct location and potentially reduces the time of validation processes.

An aspect of some embodiments of the invention relates to insertion of wires into electrical connectors by robotic manipulators. In some embodiments, the robotic manipulators comprise smart holders comprising a plurality of sensors. In some embodiments, the holders comprise are finger-like holders. In some embodiments, insertion of wires comprises manipulating a wire and receiving feedback from a plurality of sensors about the status of the wire, optionally also in relation to the electrical connector.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

Exemplary Fine motors skills and wiring

Before explaining at least one embodiment of exemplary systems and methods for automatic insertion of electrical wires into electrical terminal connectors of the invention in detail, the inventors would like to convey one of the many possible challenges in the robotic automation performance in general, and specifically, in the robotic automation for electrical wiring manipulation. The inventors have found that in order to perform correct manipulation of electrical wires into an electrical terminal connector a certain level of sensibility is required. For example, a technician or user, utilizing his somatosensory system (for example: touch), holds the wire with one hand and inserts it in the electrical terminal connector, while sometimes the other hand performs the locking actions to lock the wire in the electrical terminal connector. Furthermore, depending on the type of wire end, the user must use just the necessary force when inserting the wire into the electrical terminal connector for, on one side, inserting and keeping the wire in the electrical terminal connector while it is being locked and, on the other side, avoiding deformation of the wire due to the application of excessive force. It is also common in the art for the user to “feel” or assess that the wire is secured in location by slightingly pulling it after the locking action has been performed. In the following paragraphs exemplary actions performed by a human will be described to allow a person having skills in the art to understand the challenges when translating apparent easy tasks performed by humans into robotics.

Referring now to Figures 1A-E, showing schematic representations of an exemplary method of inserting a wire into an electrical terminal connector when performed by a human. In some embodiments, when a human performs wiring actions, he/she uses tactile feedback to secure a cable into a connector/device, a typical cycle of actions includes (see Figures 1A-1E):

• Gripping tight the wire during insertion by applying radial force on the wire (radial force - Figure 1A) and applying an insertion force (axial force - Figure IB) - before contact force is zero and it grows during insertion);

• At a certain peak force (as determined by user experience) he “feels” that the wire is inserted in the connector (peak force - Figure 1C). Usually at this point, the axial force is countered by the complete insertion of the wire in the connector;

• After the wire is secured in the connector, the user pulls back the wire (to “feel” if it is tightly secured) at a certain force (user pulls - Figure ID);

• Then, the user apply less radial force on the cable (the grip force) and allows the cable to slip in the hand in the axial direction (Figure IE). Usually, the user “feels” the slip of the cable without releasing the wire.

In some embodiments, these actions are performed using capabilities that are referred herein as Grip and Slip capabilities.

Exemplary wiring system

General information

Exemplary Sensibility: in some embodiments, the wiring system, optionally comprising arm modules and wiring-end effector modules comprise a plurality of sensors (see below) configured to monitor the interactions of the modules with the wires and/or the electrical terminal connectors. In some embodiments, the arm modules and the wiring-end effector modules are actuated using a combination of motors, sensors and software that enable compliance based mechanisms with antagonistic elastic actuation as opposed to rigid-linkage based robot grippers. In some embodiments, this allows a higher variability in gripping force control. In some embodiments, the software comprises information regarding payload weights/stiffness and structure and program that enhances the correct function (grasp planning) of the grippers without overshoot/ringing.

In some embodiments, parts of the arms and or grippers may be automatically changed for specific tasks for example to hold different tools such as tweezers or cutters.

In some embodiments, the robotic parts of the wiring system comprise fine motor skills. In some embodiments, the automated wiring system (in general) and the wiring arm(s) modules of the present invention comprises, in addition to the one or more sensors dedicated to the manipulation of the wire, a plurality of articulations that confers a plurality of degrees of freedom of movement to the system.

Referring now to Figure 2, schematically showing an exemplary wiring arm module 200 comprising a plurality of articulations or an exemplary automated wiring system, according to some embodiments of the invention. In some embodiments, the automated wiring system comprises a wiring arm module 200 comprises a plurality of articulations 202, 204, 206. In some embodiments, the articulations confers a plurality of degrees of freedom of movement. For example, articulations 202, 204, 206 can potentially confer between 4 to 8 degrees of freedom of movement as shown by the arrows. It should be understood the articulations disclosed herein are just examples to allow a person having skills in the art to understand the invention, and that greater or fewer articulations can be used. In some embodiments, the system can be Cartesian with rotary end effector or fully articulated.

In some embodiments, the wiring arm modules 200, comprise a wiring-end effector module 300, which comprise a plurality of motors and sensors that perform forces and measurements of the axial and radial forces, similarly to the actions performed by a human, in order to provide a system with high levels of dexterity and sensibility capable to perform wiring actions. In some embodiments the wiring-end effector module 300 includes one or more optical sensors, for example, one or more cameras and/or lasers scanners. In some embodiments, the wiring-end effector module 300 includes multiple 2D and/or 3D cameras.

In some embodiments, the wiring arm module is optional, meaning a more simplistic holder of the wiring-end effector module 300 can be used. In the following paragraphs, examples of an automated wiring system comprising dedicated wiring arm modules 200 will be used to explain the invention. It should be understood that other types of platforms capable of actuating the wiringend effector module 300 can be used and are also included in the scope of the invention.

In some embodiments, a typical arm has a payload of about lOKg and accuracy of better than 0.1mm. In some embodiments, a Cartesian gantry style arm or dual arms are used for main movement (XYZ) while the fine local movement is done by 2 or 3 rotating axes along with an end effector.

Exemplary wiring-end effector module 300

Referring now to Figure 3A, showing a schematic representation of an exemplary wiringend effector module 300, according to some embodiments of the invention. In some embodiments, at the wiring-end effector module 300 comprises one or more of the following parts: a wire holding element 302 and a wire locking element 304. Referring now to Figure 3B, showing a schematic representation of the parts of the wire holding element 302, according to some embodiments of the invention. In some embodiments, the wire holding element 302 comprises one or more of a base 306 comprising wire pinching element 308. In some embodiments, the wire pinching element 308 comprises two extensions 310a-b, optionally elongated finger-like extensions, which are brought together, for example, by an electrical mechanism 312 and/or by a pneumatic mechanism. In some embodiments, the wire pinching element 308 comprises a gimbal block 370 to which the two extensions 310a-b are connected (see below further explanations regarding gimbal block 370). In some embodiments, the base 306 comprises one or more motors 314/328 that allow a horizontal movement of the wire holding element 302, in the direction as schematically shown by arrow 316. In some embodiments, alternatively or additionally, the wiring arm module provides the motion along schematic arrow 316. In some embodiments, the horizontal movement shown by arrow 316 is the direction along the axis of the wire towards the electrical terminal connector. In some embodiments the motion is in line with the wire terminal port that may be, for example, at an angle of 30, 45, 90 degrees (or any angle in between) from the plane of the panel.

Referring now to Figure 3C, showing a schematic representation of the sensors located on the extensions 310a-b, according to some embodiments of the invention. In some embodiments, one or more of the extensions 310a-b comprise one or more sensors 318 configured to monitor the force applied by the elongated extensions 310a-b on the wire 320. In some embodiments sensors are embedded in the finger or the body of the end-effector. In some embodiments, those sensors allow, for example, the measurements of the axial and radial forces, similarly to the actions performed by a human, which provide a system with high levels of sensibility capable to perform wiring actions, as explained above. In some embodiments, sensors are based for example, on strain gauges, load-cells and/or others. In some embodiments, additionally or alternatively, mechanism that can sense forces or moments (i.e.: sensors) are located on the part where the extensions are connected to the device, for example the gimbal block (see 370 in Figure 3B), as shown and explained below for Figures 3D-E.

In some embodiments, the extensions 310a-b can be replaced, automatically and/or manually, to accommodate a different wire gauge.

In some embodiments, electrical mechanism 312 includes an anti-collision mechanism that protects the fingers.

In some embodiments, electrical mechanism 312 includes sensors that can measure moments that are applied by the elongated extensions 310a-b during insertion, for example moments at a value of from about 0.01NM to about 0.1NM.

Referring now to Figures 3D-E, showing schematic representations of exemplary gimbal blocks to which the extensions are connected, according to some embodiments of the invention. In some embodiments, the gimbal block 370 comprises a plurality of parts that allow the monitoring of forces applied on the extensions 310a-b. In some embodiments, the plurality of parts are one or more gimbals mounted on top of each other but having different axis of movement. In order to facilitate the explanations, two axis of movement will be described. It should be understood that more gimbals can be use, thereby providing more than two axis of movement that can be monitored. These are also part of the scope of the invention. Returning to Figure 3D, the gimbal block 370 comprises a top block 372, which connects the gimbal block 370 to the rest of the device. In some embodiments, below the top block 372 there is a top connector 374, which is connected to the top block 372 by means, for example, of screws 376. In some embodiments, one or more damping springs 396 in communication with one or more Button Axis Load Cells 378 are housed between the top block 372 and the top connector 374. In some embodiments, calibration of the Load Cells is performed by actuating the Damping Force Calibrating set screw 380. In some embodiments, below the top connector 374 there is a center block 382. In some embodiments, inserted in the top side of center block 382 there is a first gimbal axis 384, which confers the axis of movement perpendicular to the pin of the first gimbal axis 384 in the horizontal direction (see below explanations about the movement of the gimbal block). In some embodiments, inserted on the bottom side of the center block 382 there is a second gimbal axis 386 (shown in an inserted position). In some embodiments, the second gimbal axis 386 is perpendicular to the first gimbal axis 384. In some embodiments, the second gimbal axis 386 confers the axis of movement perpendicular to the pin of the second gimbal axis 386 in the horizontal direction (see below explanations about the movement of the gimbal block). In some embodiments, below the center block 382, there is a bottom connector 388, which is connected on the top to the center block 382 and on the bottom to a bottom block 390. In some embodiments, not shown in Figure 3D, another set of one or more damping springs in relation/interface with another set of one or more Button Axis Load Cells are housed between the bottom connector 388 and the bottom block 390. In some embodiments, the extensions 310a-b are connected to the bottom block 390.

In some embodiments, the device comprises one gimbal block 370 to which both extensions 310a-b are connected. In some embodiments, the device comprises two gimbal blocks 370, one gimbal block 370 for each extension, as shown for example in Figure 3E.

Referring now to Figure 3E, showing schematic representation of the exemplary movements of the gimbal block 370 and an exemplary embodiment of a device comprising two gimbal blocks, according to some embodiments of the invention. In some embodiments, as mentioned above, the gimbal block 370 comprises a first gimbal axis 384, which provides the gimbal block 370 movement in a first axis, and a second gimbal axis 386, which provides the gimbal block 370 movement in a second axis. In Figure 3E, a side view of the gimbal block 370 is shown, showing the movement (arrow 392) enabled by the first gimbal axis 384. Additionally, in Figure 3E, a front view of the gimbal block 370 is shown, showing the movement (arrow 394) enabled by the second gimbal axis 386. In some embodiments, the first gimbal axis 384 and the second gimbal axis 386 provide the gimbal block 370 with dual rotational axes at different locations. In some embodiments, these rotational axes are used with the single axis load cell to measure moments and force applied on the extensions. In some embodiments, as shown in Figure 3E, the two extensions are each separately connected to a gimbal block 370, therefore allowing measurement of different forces on each extension. In some embodiments, when the gimbal mechanisms reach their limit of rotation (movement), which optionally implies an access of force applied on an extension (for example during a possible collision of the device with the electrical panel), the system may halt the insertion operation of the wire and/or take corrective actions (moving the device).

Referring now to Figure 3F, showing a schematic representation of an exemplary wire locking element 304, according to some embodiments of the invention. In some embodiments, the wire locking element is configured to interact with the wire locking mechanism of the electrical terminal connector after the wire is inserted. In some embodiments, different electrical terminal connectors comprising different wire locking mechanisms are used, for example: screw terminal, push button and/or push-in. In some embodiments, when using an electrical terminal connector comprising a push-in locking mechanism, a wire locking element 304 is not needed and therefore not used. In some embodiments, screw terminal or screw type terminal connector secure the wire against the conductor in the electrical terminal connector by tightening a screw which closes a clamp. In some embodiments, push button terminal connector secure the wire against the conductor by a spring clamp that is opened by pressing a button. In some embodiments, releasing the button clamps the spring onto the wire. In some embodiments, similar to the push button with a spring clamp, a push-in terminal connectors allows the wire to be pressed directly into the housing without the use of a push button to open the spring. In some embodiments, according to the type of locking mechanism in the terminal connector, the wire locking element 304 will comprise a dedicated actuator 322. For example, in Figure 3F, the wire locking element 304 comprises a flat head screwdriver 322 which is used to close screw type terminal connectors. In some embodiments, the head of the actuator and/or the drill bit 322 can be replaced manually or optionally automatically (for example, by moving the device towards a replacement rack where the vertical movement 330 is used to replace the head of the actuator 322). Referring now to Figure 3G, showing schematically representations of a plurality of possible interactions of wiring-end effector modules 300 with different types of electrical terminal connector locking mechanisms.

Returning to Figure 3F, in some embodiments, the wire locking element 304 comprises a motor 324 configured to actuate the dedicated actuator 322, for example by rotating the head of the actuator 322. In some embodiments, the motor 324 and the dedicated actuator 322 are held by a base 326, which is further connected to a second motor 314/328 that performs a vertical movement, as schematically shown by arrow 330, necessary for the insertion of the dedicated actuator 322 into the electrical terminal connector locking mechanism. In some embodiments, not shown in Figure 3F, a plurality of motors are used to provide a plurality of movement directions to the wire locking element 304. In some embodiments, the wire locking element 304 is configured to move up and down, to the sides and forwards-backwards. In some embodiments, a potential advantage of providing such freedom of movement to the locking element 304 is that it allows the device to interact with a plurality of electrical terminal connectors, each having a different location for the access to the wire locking mechanism.

In some embodiments, the wire locking element 304 comprises a torque sensor configured to monitor the torqueing forces applied by the actuator on the locking mechanism of the electrical terminal connector. In some embodiments, the system comprises a database where specific torque forces related to specific locking mechanisms of electrical terminal connectors are saved. In some embodiments, the system comprises instructions to actuate the actuator according to specific parameters which specifically match the torqueing requirements of specific locking mechanism of specific electrical terminal connectors. Referring now to Figures 3H-3I, showing schematic representations of exemplary wire endeffector 300 of the automated electrical wiring system, according to some embodiments of the invention. In some embodiments, the automated electrical wiring system is used, for example, for lightning units/fixtures (see below). In some embodiments, the wire end-effector 300 comprises a mechanical wire feeder 332 comprising a dedicated motor 334 configured to feed the necessary wire 320 into the gripper 308. In some embodiments, as mentioned above, the gripper 308 comprises two (optionally finger-like) extensions 310a-b configured to pinch and hold the wire 320. In some embodiments, each extension is connected to a force providing mechanism 336a-b, configured to perform the movement of the two extensions 310a-b that actuates the pinching/holding action. In some embodiments, a dedicated motor 314/328 is connected to the force providing mechanism 336a-b. In some embodiments, optionally, the wire end-effector 300 comprises an end-wire cutter 338 configured to take out the isolation around the wire and expose the core of the wire. In some embodiments, the wire end-effector 300 optionally comprises a vacuum system (not shown) configured to pick up the waste from the end-wire cutter 338 and transport it into a waste container 340.

Referring now to Figure 3 J, showing a schematic close view of the gripper 308 and the extensions 310a-b, according to some embodiments of the invention. Same part numbers are used. In some embodiments, the gripper 308 comprises one or more sensors 318 on the extensions 310a- b configured to monitor the force applied by the gripper 308. In some embodiments, as explained above, the sensors are alternatively or additionally in the gimbal block(s) 370 that are holding the extensions. In some embodiments, as schematically shown in Figure 3 J, the gripper 308 applies and monitors forces in three main directions (marked as F , F and FM,)- In some embodiments, the forces are used for the insertion of the wire 320 into the wire terminal 344, as schematically shown on the left side of Figure 3h. In some embodiments, the forces F , FM and F ,) are from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces are of about IN.

In some embodiments, a wiring arm module 200 comprise a wiring-end effector modules 300, optionally comprises a camera 346, as shown for example in Figure 3K. It should be understood that in any of the embodiments of the wiring-end effector modules 200, a camera is optionally added. Exemplary use of wires having end terminal ferrules

Referring now to Figures 4A-B, showing schematic representation of ferrules, according to some embodiments of the invention. In some embodiments, the wires used in the automatic wiring system are wires that comprise a built-in ferrule at the distal end. Ferrules are a ring or cap 402, optionally having a metal distal end 404, used to enclose the distal end of the exposed wire in order to facilitate the handling and connection of the distal end of the wire into the electrical terminal connector. In some embodiments, the ferrule is stiff. In some embodiments, the ferrule is stiffer than the wire itself. In some embodiments, the ferrule is between about 2 and about 10 times stiffer than the wire. In some embodiments, ferrules can have different dimensions, as shown for example in Figure 4A. In some embodiments, the ferrules can have a different form of the metal part 404 at the distal end, as shown for example in Figure 4B. In some embodiments, since the ferrule comprises the cap 402, which is stiffer than the wire itself, the wiring-end effector module 300 pinches the cap 402 instead of directly pinching the wire. In some embodiments, a potential advantage of pinching the cap 402 is that it eases the manipulation of the wire during the insertion into the electrical terminal connector. Since the wire is pliant, it can happen that the wire bends during the insertion causing a deviation in the directionality of the head of the wire that needs to be inserted in the electrical terminal connector. Pinching the cap 402 potentially helps avoiding this. In some embodiments, ferrules are configured to be completely inserted into the electrical terminal connectors, meaning that the cap 402 needs to be completely inserted inside the electrical terminal connector in order to be correctly connected. In some embodiments, during the use of wires with ferrules, the method of insertion of the wire into the electrical terminal connector comprises additional steps, as will be further disclosed below. In some embodiments, the additional actions needed to be performed during the insertion of a wire including a ferrule include one or more of: the partial insertion of the ferrule into the electrical terminal connector, release or partial release of the ferrule, moving backwards of the device, re-pinching the wire at a distal location in the wire in relation to the ferrule, finishing the insertion of the wire and ferrule in the electrical terminal connector. In some embodiments, before the release of the ferrule, the system optionally partially closes the locking mechanism of the electrical terminal connector to partially hold the ferrule in place and potentially avoid the ferrule from exiting the electrical terminal connector. In some embodiments, in this case, after re-pinching the wire and before further inserting the wire in the electrical terminal connector, the system releases the locking mechanism of electrical terminal connector to allow further insertion of the wire into the electrical terminal connector. In some embodiments, the wiring-end effector module 300 comprises an additional element configured to hold the wire in place while the extensions are moved to a more distal position on the wire. In some embodiments, the additional element can be a third extension configured to be extended when needed and to hold in place the wire.

Referring now to Figure 5A, showing a flowchart of an exemplary method of wiring by an exemplary wiring-end effector module 300, according to some embodiments of the invention. In some embodiments, the elongated extensions grab the wire by applying radial force on the wires 502. In some embodiments, the force applied on the wire is from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces are of about IN. In some embodiments, the effector module brings the wire close to the connector by applying axial force 504. In some embodiments, the force applied on the wire is from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces are of about IN. In some embodiments, the wire is then inserted in the hole of the connector 506. In some embodiments, the system then senses the resistance on the wire by the fact the wire reached the end of the hole in the connector 508. In some embodiments, the system then secures the wire in the connector (see above ways to secure the wire in the connector) 510. In some embodiments, the system then pulls back wire by lightly applying contrary directional axial force, while sensing resistance from gabbing sensors, to evaluate firm connection of wire in the connector 512. In some embodiments, the system then slightly reduces the radial force on the wire while keeping holding the wire 514. In some embodiments, when the insertion of the wire was the last wire to be connected in the electrical panel, then the method ends. In some embodiments, the system then allows the wire (that is still held by the elongated extensions) to slip in the elongated extensions, without releasing the wire, while moving the mechanical arm away from the connector 516. In some embodiments, the system then continues with the wiring process, as explained therein elsewhere 518.

Referring now to Figure 5B, showing a flowchart of an exemplary method of wiring by an exemplary wiring-end effector module when the wire comprises ferrule, according to some embodiments of the invention. In some embodiments, the extensions grab the wire by applying radial force on the ferrule 520. In some embodiments, the force applied on the ferrule is from about 3N to about 110N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces are of about 0.5N. In some embodiments, the effector module brings the ferrule close to the connector by applying axial force 522. In some embodiments, the force applied on the wire is from about 3N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about ION, about 12N. In some embodiments, the resolution of any of the above forces are of about 0.25N. In some embodiments, the ferrule is then partially inserted in the hole of the connector 524. In some embodiments, optionally, the system partially closes the locking mechanism in the electrical terminal connector to hold the ferrule in place 526. In some embodiments, the wire with the ferrule are held in place 528. In some embodiments, this is performed by one or more additional elements as disclosed above. In some embodiments, the extensions are actuated to release the ferrule 530. In some embodiments, then the device is moved backwards in line with the wire 532. In some embodiments, the extensions re-grab the wire on the wire itself 534. In some embodiments, optionally, the system opens the previously partially closed locking mechanism of the electrical terminal connector 536. In some embodiments, the system then applies axial force to completely inserting the ferrule into the electrical terminal connector 538. Flowchart continues in Figure 5C following the letter A. In some embodiments, the system then senses the resistance on the wire by the fact the wire reached the end of the hole in the connector 540. In some embodiments, the system then secures the wire in the connector (see above ways to secure the wire in the connector) 542. In some embodiments, the system then pulls back wire by lightly applying contrary directional axial force, while sensing resistance from gabbing sensors, to evaluate firm connection of wire in the connector 544. In some embodiments, the system then slightly reduces the radial force on the wire while keeping holding the wire 546. In some embodiments, when the insertion of the wire was the last wire to be connected in the electrical panel, then the method ends. In some embodiments, the system then allows the wire (that is still held by the elongated extensions) to slip in the elongated extensions, without releasing the wire, while moving the mechanical arm away from the connector 548. In some embodiments, the system then continues with the wiring process, as explained therein elsewhere 550.

In some embodiments, the parameters sensed by the one or more sensors, either in the extensions, on the gimbal block or anywhere else in the system, for example force, thresholds, motion values relating to the wire and the insertion process are saved in a data base.

Exemplary use of the system for lighting wiring fixture

In the following paragraphs, an exemplary use of the automated wiring system will be disclosed. It should be understood that the following is just an example of use of the automated wiring system brought in order to allow a person having skills in the art to understand the invention and should not be limiting in any way.

In some embodiments, the automated electrical wiring system is used for the wiring of lighting units. Referring now to Figure 6 showing a schematic representation of an automated electrical wiring for lightning units 600, according to some embodiments of the invention. In some embodiments, the automated electrical wiring for lightning units 600 comprises a base 602 on which the different parts of the automated electrical wiring for lightning units 600 are mounted. In some embodiments, the automated electrical wiring for lightning units 600 comprises at least one robotic arm 604 comprising a wire end-effector 606. In some embodiments, the automated electrical wiring for lightning units 600 optionally comprises a depth camera 608 configured to monitor the wiring actions of the system. In Figure 6 it is also shown an exemplary lighting panel 610 in the location where the wiring process is performed. In some embodiments, additionally, a camera 612 is used to monitor the wiring process. Also seen in Figure 6, a controller 614 and a user interface 616 for controlling the system.

Various embodiments and aspects of the present invention as delineated hereinabove and as claimed in the claims section below find experimental support in the following Exemplary Embodiments.

EXEMPLARY EMBODIMENTS

Reference is now made to the following Exemplary Embodiments, which together with the above descriptions illustrate some embodiments of the invention in a non-limiting fashion.

Referring now to Figure 7, showing a graph describing the exemplary phases of the insertion of a wire into an electrical terminal connector as identified by the sensors in the gripper, according to some embodiments of the invention. In some embodiments, the system is configured to identify the different phases of the insertion of the wire into the electrical terminal connector, as further disclosed above. The graph in Figure 7 shows the force sensed by the sensors on the fingerlike extensions 310a-b in the gripper 308 in relation to the held wire. In some embodiments, the phases are:

Phase A: movement forward towards the electrical terminal connector. In some embodiments, at this phase, the wire is held by the gripper 308 and the gripper 308 is moving forward towards the electrical terminal connector. In some embodiments, at the beginning the sensed force is the same as the wire has not met any obstruction. In some embodiments, at some point, the wire meets the electrical terminal connector, and the sensors begin to sense an increase in the sensed force. Once reached a certain peak, the system will move to the next phase. In some embodiments, the peak may depend and optionally set based on type of wire and/or the type of electrical terminal connector. In some embodiments, the relation between the type of wire, the type of connector and the “sensed” forces is learned by the system and stored in a dedicated database. In some embodiments, an Al algorithm is used to generate these peak values based on learned data. Phase B: movement backwards from the electrical terminal connector. In some embodiments, once a certain peak has been reached, the gripper 308 will begin moving backwards while still holding the wire but without actually pulling the wire with it. In some embodiments, as shown in the graph, the sensed forces decrease drastically, as the gripper loosens the grip.

Phase C: movement backwards from the electrical terminal connector while pulling the wire. In some embodiments, in order to assess correct connection between the wire and the electrical terminal connector, the gripper gently holds the wire while continuing moving backwards from the electrical terminal connector. In some embodiments, at this point, two possible things can happen: 1. the wire is correctly connected and will not move causing the gripper to slip over the connected wire; or 2. the wire is not connected correctly and will be pulled out the electrical terminal connector. In some embodiments, as mentioned above, the values are learned and/or adjusted after each attempt.

In some embodiments, different types of electrical terminal connectors and different types of wires will be characterized with different forces, which will be characterized by different forces sensed by the gripper. In some embodiments, the system comprises a database in which the different combinations of different types of electrical terminal connectors and different types of wires are kept, and according to the input provided by the user, the system will actuate the gripper accordingly.

Referring now to Figures 8A-C, showing three different examples of sensed forces by the gripper in three different scenarios, according to some embodiments of the invention. Figure 8A shows an example of what the sensors sense during the movement backwards of the gripper and the wire did not connect at all with the electrical terminal connector. In this case, there is no increase of the sensed force since the wire does not resist the pulling of the gripper.

Figure 8B shows an example of what the sensors sense during the movement backwards of the gripper and the wire did not connect correctly with the electrical terminal connector. In this case, at the beginning, the gripper begins to move backwards until the wire resists the pulling, which is translated to an increase in the sensed force. At some point, because the wire is not properly connected, it will detach from the electrical terminal connector, which is evidenced by the sudden decrease in the sensed force, and then return to the same levels as in the beginning.

Figure 8C shows an example of what the sensors sense during the movement backwards of the gripper and the wire did connect correctly with the electrical terminal connector. In this case, at the beginning, the gripper begins to move backwards until the wire resists the pulling, which is translated to an increase in the sensed force. At some point, because the wire is properly connected, the gripper will begin slipping over the wire, which is evidenced by the reduction of the sensed force on the gripper at the end of the graph.

Referring now to Figure 9, showing a plurality of test experiments for the characterization of exemplary scenarios, according to some embodiments of the invention. As previously disclosed, at the beginning there is movement of the gripper without resistance from the wire, therefore the input from the force sensor stays stable. Then, once the wire enters the electrical terminal connector, there is spike in the input from the sensors due to the resistance between the wire and the connector. Then, the device begins to pull the wire backwards in order to assess the connection between the wire and the electrical terminal connector. This part is characterized by a sudden decrease in the input received from the sensor, as seen in Figure 9. Then, according to the outcome of the connection between the wire and the electrical terminal connector, different inputs are received from the sensor. In Test 1, the wire missed the connector, as can be seen by the unchanged graph. In Test 2, the wire disconnected from the connector during the pulling backwards of the wire. In test 3, the wire connected perfectly to the connector, and the gripper slipped over the wire during the backwards movement. In Test 4 the wire disconnected from the connector during the pulling backwards of the wire. The abovementioned graphs are exemplary experiments provided to allow a person having skills in the art to understand the invention and should not be limiting in any way.

As used herein with reference to quantity or value, the term “about” means “within ± 20 % of’.

The terms “comprises”, “comprising”, “includes”, “including”, “has”, “having” and their conjugates mean “including but not limited to”.

The term “consisting of’ means “including and limited to”.

The term “consisting essentially of’ means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a compound” or “at least one compound” may include a plurality of compounds, including mixtures thereof.

Throughout this application, embodiments of this invention may be presented with reference to a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as “from 1 to 6” should be considered to have specifically disclosed subranges such as “from 1 to 3”, “from 1 to 4”, “from 1 to 5”, “from 2 to 4”, “from 2 to 6”, “from 3 to 6”, etc.; as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein (for example “10-15”, “10 to 15”, or any pair of numbers linked by these another such range indication), it is meant to include any number (fractional or integral) within the indicated range limits, including the range limits, unless the context clearly dictates otherwise. The phrases “range/ranging/ranges between” a first indicate number and a second indicate number and “range/ranging/ranges from” a first indicate number “to”, “up to”, “until” or “through” (or another such range-indicating term) a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numbers therebetween.

Unless otherwise indicated, numbers used herein and any number ranges based thereon are approximations within the accuracy of reasonable measurement and rounding errors as understood by persons skilled in the art.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

It is the intent of the applicant(s) that all publications, patents and patent applications referred to in this specification are to be incorporated in their entirety by reference into the specification, as if each individual publication, patent or patent application was specifically and individually noted when referenced that it is to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. In addition, any priority document(s) of this application is/are hereby incorporated herein by reference in its/their entirety.